Chair mat

ABSTRACT

A chair mat includes a first decorative layer, the first decorative layer being composed of melamine-formaldehyde impregnated decorative sheet. The chair mat also includes a central core layer including a top first surface and a bottom second surface, the central core layer being composed of at least one resin impregnated sheet. The first decorative layer is coupled to the top first surface of the central core layer. The chair mat also includes a second decorative layer coupled to the bottom second surface of the central core layer, the second decorative layer being composed of a melamine-formaldehyde impregnated decorative sheet.

CROSS REFERENCE TO RELATE APPLICATION

The application claims the benefit of U.S. Provisional PatentApplication Ser. No. 60/929,480, entitled “CHAIR MAT”, filed Jun. 29,2007.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a chair mat. In particular, the inventionrelates to a chair mat composed of an engineered, resin impregnatedlaminate including opposed decorative surfaces of melamine-formaldehydeimpregnated decorative sheets with a core layer of phenolic resinimpregnated Kraft paper.

2. Description of the Related Art

Chair mats are common products found in both commercial office locationsand home office locations. They provide protection to the underlyingcarpeting or flooring surface, while also providing a flat supportsurface upon which one may readily move a chair supported thereon.However, and as anyone who has worked within an office is certainlyaware, chair mats are limited in their durability and aesthetics.

The most common type of chair mat is molded from a piece of pliableplastic to include a relatively flat upper surface and a lower surfacewith a series of downwardly extending nubs. In view of the pliablenature of these chair mats, it is necessary that they be utilized on asupporting surface which provides ample support for the chair mat. Wherethe chair mat is placed upon a cushioned, carpeted surface, the floormat will consistently flex in a manner causing exaggerated cracking ofthe plastic of the floor mat. With this flexing also comes limited, orencumbered, movement of the chair as it is rolled upon the floor mat.

In addition to the requirement that these pliable floor mats be placedupon relatively hard supporting surfaces (for example, commercial gradecarpeting bound to a hard sub floor, hardwood floors or bare concretesurfaces), these plastic chair mats will readily crack over time,negatively affecting their appearance and necessitating replacementthereof. Since the underside of the floor mat is provided with nubs andnot a flat surface similar to the top surface, once the top surface isdestroyed, the entire floor mat must be replaced.

Other chair mats are known that are made of more durable materials, forexample, wood. However, these chair mats are relatively expensive andare generally thicker than is truly desirable.

With the foregoing in mind, an improved floor mat is provided inaccordance with the present invention.

SUMMARY OF THE INVENTION

It is, therefore, an object of the present invention to provide a chairmat including a first decorative layer, the first decorative layer beingcomposed of melamine-formaldehyde impregnated decorative sheet. Thechair mat also includes a central core layer including a top firstsurface and a bottom second surface, the central core layer beingcomposed of at least one resin impregnated sheet. The first decorativelayer is coupled to the top first surface of the central core layer. Thechair mat also includes a second decorative layer coupled to the bottomsecond surface of the central core layer, the second decorative layerbeing composed of a melamine-formaldehyde impregnated decorative sheet.

It is also an object of the present invention to provide a chair matincluding a large rectangular area with a lip portion extendingtherefrom.

It is also another object of the present invention to provide a chairmat wherein the first decorative layer is alpha-cellulose decorativepaper and the second decorative layer is alpha-cellulose decorativepaper.

It is also a further object of the present invention to provide a chairmat wherein the first decorative layer and the second decorative layerare impregnated with melamine-formaldehyde resin.

It is another object of the present invention to provide a chair matwherein the central core layer is composed of a plurality of sheets ofresin impregnated paper.

It is still another object of the present invention to provide a chairmat wherein the central core layer is impregnated with phenolic resin.

It is also an object of the present invention to provide a chair matwherein the central core layer is composed of 10 to 12 sheets of kraftpaper.

It is a further object of the present invention to provide a chair matincluding first and second overlay layers respectively positioned on topof the first decorative layer and the second decorative layer.

It is still a further object of the present invention to provide a chairmat wherein the first overlay layer is composed of melamine-formaldehyderesin impregnated paper and the second overlay layer is composed ofmelamine-formaldehyde resin impregnated paper.

It is yet a further object of the present invention to provide a chairmat wherein the first overlay layer and the second overlay layer aretreated with aluminum oxide.

It is also an object of the present invention to provide a chair matwherein the aluminum oxide is selectively applied in a manner providingfor desired wear and clarity characteristics.

It is also another object of the present invention to provide a chairmat wherein the first and second overlay layers are approximately 70%impregnated.

It is also a further object of the present invention to provide a chairmat wherein the chair mat is approximately ¼″ to approximately ⅜″ thick.

It is another object of the present invention to provide a chair matwherein the chair mat is approximately 5/16″ thick.

It is a further object of the present invention to provide a chair matwherein the chair mat is fire rated Class A.

It is also an object of the present invention to provide a chair matwherein the first decorative layer and the second decorative layer areof the same aesthetic design.

It is still another object of the present invention to provide a chairmat wherein the first decorative layer and the second decorative layerare of different aesthetic designs.

It is also another object of the present invention to provide a chairmat wherein the chair mat is reversible for exposing either the firstdecorative layer or the second decorative layer.

It is a further object of the present invention to provide a chair matwherein the chair mat is stain and chemical resistant.

It is also an object of the present invention to provide a chair matwherein the chair mat is static dissipative.

Other objects and advantages of the present invention will becomeapparent from the following detailed description when viewed inconjunction with the accompanying drawings, which set forth certainembodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a chair mat in accordance with thepresent invention.

FIG. 2 is a schematic showing the various layers of the present chairmat.

FIG. 3 is a detailed view of the various sheets making up the centralcore layer.

FIG. 4 is a perspective view of the present chair mat in accordance withan alternate embodiment.

FIG. 5 is a schematic showing the various layers of the chair mat shownwith reference to FIG. 4.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The detailed embodiments of the present invention are disclosed herein.It should be understood, however, that the disclosed embodiments aremerely exemplary of the invention, which may be embodied in variousforms. Therefore, the details disclosed herein are not to be interpretedas limiting, but merely as a basis for teaching one skilled in the arthow to make and/or use the invention.

In accordance with the present invention, and with reference to FIGS. 1,2 and 3, a chair mat 10 in accordance with the present invention isdisclosed. The chair mat 10 includes a first decorative layer 12 (withthe lead lines of FIG. 1 pointing to the aesthetics thereof asdesignated by the hatching therein) composed of a melamine-formaldehydeimpregnated decorative sheet, a central core layer 14 having a top firstsurface 16 and a bottom second surface 18, and a second decorative layer20 composed of a melamine-formaldehyde impregnated decorative sheet. Thefirst decorative layer 12 is secured to the top first surface 16 of thecentral core layer 14 and the second decorative layer 20 is secured tothe bottom second surface 18 of the central core layer 14.

As those skilled in the art will certainly appreciate, a chair mat 10 isformed for positioning behind a desk such that an individual may movehis or her chair freely thereabout without unduly wearing upon theunderlying flooring surface. As such, and in accordance with a preferredembodiment, the chair mat 10 includes a large square, or rectangular,area 22, upon which the chair itself sits during use. The large square,or rectangular, area 22 includes first, second, third and fourth sides24, 26, 28, 30. A rectangular lip portion 32 extends from the first side24 for positioning under the desk where the chair mat 10 is positioned.Depending upon the size of the desk and the room in which the desk ispositioned, a chair mat 10 may vary in size from approximately 48″×48″to approximately 60″×60″. While a shape is disclosed herein inaccordance with a preferred embodiment of the present invention, thoseskilled in the art will appreciate the shape may be varied withoutdeparting from the spirit of the present invention.

In accordance with a preferred embodiment of the present invention, andbased upon the materials used in the construction thereof, the corners34 of the chair mat 10 are formed with a radius of curvature fromapproximately 0.5 inch to approximately 2 inches.

As to the first decorative layer 12 and the second decorative layer 20,they are similarly manufactured from high quality 65-160grams/meters²basis weight, printed or non-printed, alpha-cellulosedecorative paper treated or non-treated with an aqueous solution ofmelamine-formaldehyde resin. As those skilled in the art will appreciatethe first decorative layer 12 and the second decorative layer 20 may bepretreated with melamine-formaldehyde resin or used untreated therebyallowing the resin from the first and second overlay layers 36, 38 torespectively pass therethrough and impregnate the first and seconddecorative layers 12, 20. The alpha-cellulose decorative paper thatultimately makes up the first and second decorative layers 12, 20 is cutinto sheets for subsequent consolidation with the other layers of thepresent chair mat 10. The alpha-cellulose paper of the first and seconddecorative layers 12, 20 may include a solid color, a decorative design,or a photogravure reproduction of natural materials, such as, wood,marble, leather, etc. The decorative characteristics of thealpha-cellulose paper of the first and second decorative layers 12, 20are revealed as the viewable decorative design upon completion of thepresent chair mat 10.

The central core layer 14 positioned between the first and seconddecorative layers 12, 20 is preferably composed of a plurality of sheets40 of phenolic resin impregnated paper, although other materials may beused without departing from the spirit of the present invention. Inaccordance with a preferred embodiment of the present invention, thecentral core layer 14 includes a plurality of sheets of 120-299grams/meters² dry phenolic resin impregnated Kraft paper. The Kraftpaper is impregnated throughout with a substantially cured phenolicresin which has been partially cross-linked during the initiallaminating step.

In accordance with a preferred embodiment, the central core layer 14 iscomposed of 10-12 sheets 40 of phenolic resin impregnated Kraft paper,depending upon the desired final thickness and the weight of the Kraftpaper that is being used. Those skilled in the art will appreciatethinner sheets are better impregnated with the phenolic resin as theytend to saturate better, therefore, resulting in a more dense and strongcomposite after pressing. In addition, and in accordance with apreferred embodiment, the sheets 40 making up the central core layer 14are flipped alternately so that top surfaces 40 a of the sheets 40 faceeach other and the bottom surfaces 40 b of the sheets 40 face eachother. This balances the final product by ensuring the saturation levelsof the paper sheets 40 are well balanced and do not cause warping in theresulting chair mat 10. As a result an even number of sheets should beused to properly balance the central core layer 14.

In accordance with a preferred embodiment, the sheets 40 making up thecentral core layer 14 are commonly 5-foot by 12-foot sheets and areflipped about an axis extending along the length (that is, the 12-footdimension). The sheets 40 are flipped in this manner because it is knownto those skilled in the art that Kraft paper sheets commonly used in themanufacture of laminates expand more in width than in length due tofiber orientation and paper construction. As a result, flipping ofalternate sheets 40 in accordance with a preferred embodiment of thepresent invention results in a central core layer 14 which is highlybalance by distributing imperfections in the treated Kraft paper amongopposite sides of the resulting central core layer 14.

As briefly discussed above, it is contemplated the core layer may becomposed of other materials without departing from the spirit of thepresent invention. For example, a plied fiberboard may be employed. Sucha construction would preferably be composed of two thin fiberboardsheets glued together along their facing surfaces. Similarly, a corelayer composed of cement board or a fiberglass composite could beutilized without departing from the spirit of the present invention. Itis also contemplated the core layer may be composed of plywood, GRIDCORE(that is, an engineered sheet material composed of honeycomb shapedcavities adding structural stability to the material) or otherengineered plastic materials. However, it is considered that each ofthese alternate core materials is burdened with the problem ofaesthetically undesirable edge characteristics when the product isultimately cut into its desired shaped.

In accordance with a preferred embodiment, first and second overlaylayers 36, 38 are respectively positioned over both the first decorativelayer 12 and the second decorative layer 20. The first and secondoverlay layers 36, 38 are preferably composed of a sheet ofmelamine-formaldehyde resin impregnated paper. The paper is preferably60%-80% impregnated, more preferably approximately 70% impregnated. Whenthe chair mat 10 is fully heated and pressed as described below, thefirst and second overlay layers 36, 38 become translucent, fullyexposing both the first and second decorative layers 12, 20. In order toenhance the wear resistance of the first and second overlay layers 36,38. They preferably contain aluminum oxide dispersed in a manner wellknown to those skilled in the art.

More particularly, the wear resistance properties of the present chairmat 10 are achieved by optimizing the application of aluminum oxide tothe first and second overlay layers 36, 38. As those skilled in the artwill appreciate, various techniques are employed in the application ofaluminum oxide to the overlay layers.

In accordance with a first technique, the aluminum oxide is incorporatedinto the paper of the overlay layer prior to the application ofmelamine-formaldehyde resin thereto. This offers the advantage ofproviding greater clarity for viewing of the decorative layer, but,because the aluminum oxide is not actually upon the outer surface of theoverlay layer, offers a low level of wear resistance. In accordance witha second technique, untreated paper is treated with aluminum oxideduring the melamine-formaldehyde resin impregnation process by eitherspreading the aluminum oxide upon the paper after it has been drawnthrough the melamine-formaldehyde resin bath or incorporating thealuminum oxide directly into the melamine-formaldehyde resin bath. Thistechnique provides for substantial wear resistance (that is, until theouter surface is worn through), but the application of the aluminumoxide to the outer surface of the overlay layer detracts from theclarity of the resulting laminate. A third technique takes advantage ofboth the first and second techniques by combining the techniques andutilizing a paper that is pretreated with aluminum oxide and issubsequently treated with additional aluminum oxide during themelamine-formaldehyde application.

In accordance with a preferred embodiment, aluminum oxide is applied tothe first and second overlay layers 36, 38 of present chair mat 10 in amanner without adversely affecting clarity thereof while similarlyimproving the wear characteristics of the chair mat 10. With this inmind, aluminum oxide will be applied to the first and second overlaylayers 36, 38 of the chair mat 10 by utilizing aluminum oxide finer(that is, approximately 25 micron aluminum oxide as opposed to 80 micronto 100 micron aluminum oxide commonly employed in the flooring industry)than that commonly utilized within the flooring industry, but utilizingless aluminum oxide than is commonly utilized within the flooringindustry. In addition, and as those skilled in the art will certainlyappreciate, the wear resistance of the chair mats 10 in accordance withthe spirit of the present invention may be engineered to accommodatevarious needs and uses by simply adjusting the technique used in theapplication of the aluminum oxide to the overlay layer employed in themanufacture of the chair mat 10. As a result, chair mats 10 may bereadily manufactured which are capable of offering wear resistancebetween approximately 400 and approximately 3,000 cycles NEMA.

By constructing the present chair mat 10 of a laminated structure thatis balanced in a desirable manner (that is, substantially identicalfirst and second decorative layers 12, 20 and substantially identicalfirst and second overlay layers 36, 38 on opposite sides of a centralcore layer 14 composed of alternately flipped sheets of Kraft paper),the present chair mat 10 is not susceptible to warping or bendingresulting from uneven forces being applied to both the top and bottomsurfaces of the chair mat 10.

Once the first decorative layer 12 (that is, the first decorative papersheet), the central core layer 14 and the second decorative layer 20(that is, the second decorative paper sheet), as well as the first andsecond overlay layers 36, 38 are manufactured, a laminate lay-up isconstructed. The laminate lay-up includes, in order of stacking, thefirst overlay layer 36, the first decorative layer 12, the central corelayer (composed of 10-12 sheets of phenolic impregnated Kraft paper) 14,the second decorative layer 20 and the second overlay layer 38. Thelayers are stacked and placed between steel plates. The laminate lay-upstack is then subjected to temperatures in the range of 121° Celsius to160° Celsius and pressures of approximately about 56.24 kilograms/cm² toapproximately 112.48 kilograms/cm² for a time sufficient to consolidatethe laminate and cure the resins (generally about twenty-five minutes toan hour). The pressure and heat force the resin in the paper sheets toflow, cure and consolidate the sheets into a unitary laminated mass.Generally, more than one laminate is formed at one time. Multiplelaminates are formed by inserting a plurality of assembled sheetsbetween press plates in a stack. Release sheets may be positionedbetween the assembled sheets to separate the various laminates stackedtogether. After consolidation, the release sheet allows the individuallaminates to be separated.

Once the consolidated mass composed of the first overlay layer 36, thefirst decorative layer 12, the central core layer 14, the seconddecorative layer 20 and the second overlay layer 38 are formed, they arecut in a desired shape of a chair mat 10 and ready for usage. Inparticular, and in accordance with a preferred embodiment, theconsolidated mass is cut into the form of a chair mat 10 utilizingconventional CNC (computer numerically controlled) machinery. As aresult, a variety of chair mat shapes and sizes may be offered by simplyadjusting the parameters input into the CNC machine. The geometries mayfall anywhere within the 5′×12′ envelope contemplated for themanufacture of the consolidated mass sheets that are ultimately cut intothe chair mat 10 of the present invention.

The present chair mat 10 provides an engineered laminated structureobviating many of the shortcomings of the prior art. First, given therigidity of the laminated chair mat 10 of the present invention, it maybe placed upon a variety of surfaces without worrying that theunderlying surface is too cushioned. In addition, it will only beapproximately ¼″ to ⅜″ thick, preferably approximately 5/16″ thick, andas such will not present a problem with people tripping thereover. Inaddition, the thickness of the chair mat may be readily varied byincreasing or decreasing the number of sheets of Kraft paper employed inthe central core layer 14 thereof.

The present chair mat 10 has also been engineered to provide a balancedstructure inhibiting the undesirable warping or “rolling up” of edges ofthe chair mat 10. This is achieved by providing a central core layer 14having identical decorative layers 12, 20/overlay layers 36, 38 appliedon opposite sides thereof in an equal and balanced manner. As such,forces generated through the expansion or contraction of either side arebalanced by a counter flexing on the opposite side. As a result, thechair mat 10 will remain flat regardless of which type of surface it isplaced on.

As discussed above, the present chair mat 10 also provides decorationson both sides thereof by providing the same or different decorativesheets to the first and second decorative layers 12, 20 of the presentchair mat 10. As such, a user can simply flip the chair mat 10 over whenone side is worn or the user is tired of the aesthetic appearance ofthat side. As a result, the user may achieve two chair mats in the formof one. In accordance with a preferred embodiment of the presentinvention, designs such as, but not limited to, sports logos, universityemblems, corporate logos, personal pictures, building maps, etc. may beincorporated into the decorative layers 12, 20 of the present chair mat10.

The materials used in the construction of the present chair mat 10 alsoresult in a chair mat 10 that may be fire rated as a Class A materialbecause the resulting laminate structure is resistance to burning. Inaddition, the melamine-formaldehyde resin of the decorative layer andoverlay layer is highly chemical resistance and stain resistant.

Referring to FIGS. 4 and 5, and in accordance with an alternateembodiment, the laminate chair mat 110 of the present invention may beformulated with static dissipative characteristics. As such, users ofthe present chair mat 110 will avoid problems associated with shock ashe or she rolls his chair about the chair mat 110 in the environment ofa synthetic carpet material. In accordance with a preferred embodiment,the static dissipative characteristics are imparted to the chair mat 110by incorporating carbon fibers 150 into the paper sheets malting up thefirst and second overlay layers 136, 138. However, it is contemplatedthe carbon fibers may also be incorporated into the decorative layers112, 120 or the core layer 114.

While the preferred embodiments have been shown and described, it willbe understood that there is no intent to limit the invention by suchdisclosure, but rather, is intended to cover all modifications andalternate constructions falling within the spirit and scope of theinvention.

1. A chair mat, comprising: a first decorative layer, the firstdecorative layer being composed of a melamine-formaldehyde impregnateddecorative sheet; a central core layer including a top first surface anda bottom second surface, the central core layer being composed of atleast one resin impregnated sheet, wherein the first decorative layer iscoupled to the top first surface of the central core layer; and a seconddecorative layer coupled to the bottom second surface of the centralcore layer, the second decorative layer being composed of amelamine-formaldehyde impregnated decorative sheet.
 2. The chair mataccording to claim 1, further including a large rectangular area with alip portion extending therefrom.
 3. The chair mat according to claim 1,wherein the first decorative layer is alpha-cellulose decorative paperand the second decorative layer is alpha-cellulose decorative paper. 4.The chair mat according to claim 3, wherein the first decorative layerand the second decorative layer are impregnated withmelamine-formaldehyde resin.
 5. The chair mat according to claim 1,wherein the central core layer is composed of a plurality of sheets ofresin impregnated paper.
 6. The chair mat according to claim 5, whereinthe central core layer is impregnated with phenolic resin.
 7. The chairmat according to claim 5, wherein the central core layer is composed of10 to 12 sheets of Kraft paper.
 8. The chair mat according to claim 1,further including first and second overlay layers respectivelypositioned on top of the first decorative layer and the seconddecorative layer.
 9. The chair mat according to claim 8, wherein thefirst overlay layer is composed of melamine-formaldehyde resinimpregnated paper and the second overlay layer is composed ofmelamine-formaldehyde resin impregnated paper.
 10. The chair mataccording to claim 9, wherein the first overlay layer and the secondoverlay layer are treated with aluminum oxide.
 11. The chair mataccording to claim 10, wherein the aluminum oxide is selectively appliedin a manner providing for desired wear and clarity characteristics. 12.The chair mat according to claim 9, wherein the first and second overlaylayers are approximately 70% impregnated.
 13. The chair mat according toclaim 1, wherein the chair mat is approximately ¼″ to approximately ⅜″thick.
 14. The chair mat according to claim 11, wherein the chair mat isapproximately 5/16″ thick.
 15. The chair mat according to claim 1,wherein the chair mat is fire rated Class A.
 16. The chair mat accordingto claim 1, wherein the first decorative layer and the second decorativelayer are of the same aesthetic design.
 17. The chair mat according toclaim 1, wherein the first decorative layer and the second decorativelayer are of different aesthetic designs.
 18. The chair mat according toclaim 1, wherein the chair mat is reversible for exposing either thefirst decorative layer or the second decorative layer.
 19. The chair mataccording to claim 1, wherein the chair mat is stain and chemicalresistant.
 20. The chair mat according to claim 1, wherein it is staticdissipative.